Shoe made from a sock and a reinforcing structure

ABSTRACT

The invention relates to a shoe comprising, from within the shoe, a first flexible textile layer ( 10, 16 ) forming a sock, and a reinforcing structure ( 3 ) in which the textile layer is arranged and to which it is fixed using fixing means.

The invention relates to the manufacture of an article of clothing, such as a shoe or, more generally, an article of footwear.

The manufacture of a shoe, irrespective of its form, requires using a number of elements, on the order of several dozens, sometimes up to 45, and involves a number of steps of assembling, bonding, and affixing all such elements to one another.

Therefore, the assembly of a shoe is a time-consuming process, and requires special, heavy, and expensive tools.

The invention provides a novel structure for a shoe, or for an article of footwear, as well as a method for making a shoe or an article of footwear.

To this end, the invention first provides a textile element comprising a sock foot, a first heel, a first upper, a second heel, arranged at the top of said upper, and a second upper in the extension of the second heel. For example, the second upper is connected stitchlessly to the first upper.

An opening may be made in the second upper, in order to provide a passageway for one or more lacing cords.

The invention also relates to a shoe comprising, from within the shoe, a first flexible textile layer, forming a sock, and a reinforcing structure in which the textile layer is arranged and to which it is fixed by fixing means.

The textile layer may be arranged so as to be:

-   -   removable with respect to the reinforcing structure, to which it         is connected by means such as snap-fasteners, buttons,         hook-and-loop surfaces, or the like; or     -   irremovable with respect to the reinforcing structure, to which         it is connected, for example, by gluing, heat-sealing, or any         other means.

The shoe may further comprise a second textile layer, the reinforcing structure being arranged between the first textile layer and the second textile layer.

The second textile layer is made, for example, in the extension of the first textile layer, the first and second layers being connected stitchlessly.

According to an embodiment, the reinforcing structure comprises at least one sole and lateral reinforcing elements.

This reinforcing structure may further comprise at least one toe-cap element and/or a stiffener-forming element.

The reinforcing structure may be flexible; it is for example made of a fiber-based material.

The invention also relates to a method for making a shoe, using a sock and a reinforcing structure comprising at least one sole and at least one lateral reinforcing structure, comprising the steps of:

-   -   fitting the sock onto a foot-shaped form;     -   positioning the reinforcing structure on the sock, in contact         therewith, and fixing it to said sock using fixing means.

According to a particular embodiment, the sock is a textile element as already described above.

The reinforcing structure is irremovably fixed to the sock, for example by gluing, heat sealing, or the like.

Alternatively, the reinforcing structure is removably fixed to the sock using snap-fasteners, buttons, hook-and-loop surfaces, or the like.

According to one embodiment, which enables an adaptation of the reinforcing structure during the very making of the shoe, this reinforcing structure comprises a first portion and a second portion which, prior to attachment to the sock, are displaceable relative to one another, so as to adjust the reinforcing structure to the foot-shaped form.

Irrespective of the embodiment envisioned, at least a portion of the textile material used can comprise one or more physical and/or chemical properties enabling it to ensure odor control, fungicidal control, moisture absorption, skin healing, imperviousness or water-repellency, resistance to intrusion of foreign bodies, abrasion resistance, elasticity, or the like.

At least two zones of the textile material can have one or more different physical or chemical properties. For example, at least two zones of the textile material can be zones having different levels of imperviousness.

FIGS. 1A and 1B show a textile element, or sock, which may be implemented within the scope of the present invention;

FIGS. 2A-2C illustrate steps in the making of an element of the type shown in FIGS. 1A-1B;

FIGS. 3A-3E show various embodiments of the reinforcing means, which can be implemented within the scope of the present invention;

FIGS. 4A and 4B show a preform, on which a shoe according to the invention may be embodied;

FIGS. 5A and 5B show a first step of an embodiment of a method according to the invention;

FIGS. 6A and 6B show a second step of an embodiment of a method according to the invention.

FIGS. 7A-7B show a second step of an embodiment of a method according to the invention, and FIG. 7C shows an example of a shoe obtained by the method according to the invention;

FIG. 8 shows another example of a shoe obtained by the method according to the invention; and

FIGS. 9A-9B show steps of another embodiment of a method according to the invention.

Firstly described is the making of a textile element 2, which can be used in the making of an article of footwear according to the invention.

This element is shown schematically in FIGS. 1A and 1B.

It comprises a first portion forming a sock foot 10, provided with an end 12 and a heel 14. This foot is extended by an upper 16. These elements 10, 12, 14, 16 constitute the typical structure of a sock. However, in the sock used here, the upper 16 is extended by a second heel 18, and then by a second upper 20 having an end opening 22. This element, when arranged on a planar surface, as in FIG. 1A, has a substantially U-shape.

An opening 21 may be provided in the second upper 20, in order to let the lace-forming cords pass therethrough.

The assembly is substantially symmetrical with respect to a plane C-C′, the trace of which is seen in FIG. 1B, and which is substantially perpendicular to the axis of the upper 16. The symmetry does not involve the end 12 and the opening 22.

Described with reference to FIGS. 2A-2C are steps of a method for making an element such as described above with reference to FIGS. 1A and 1B.

A substantially cylindrical textile element 1, having a diameter corresponding substantially to the diameter of the upper 16, is made on a cylinder 5 (FIG. 2A), for example by knitting, weaving, or braiding.

The element 1, when finished, is removed from the support 5, and two notches or cutouts 4, 8 are made thereto (FIG. 2B), with the view of positioning the heels 14, 18 therein. FIG. 2B already shows the opening 22 that will end the element 10.

The cutouts 4, 8 enable the ends of the textile element 1 to be spaced apart with respect to its cylindrical axis of symmetry X, X′.

Textile portions 14, 18 forming the heels and a portion 12 forming the end of the foot of the sock can then be fixed in the openings made from the notches 4, 8 (FIG. 2C). An element of the type described above with reference to FIGS. 1A and 1B can thus be obtained.

The textile used for the element 2 and the method described above may be uniform for the entire sock. This textile can have one or more specific physical and/or chemical properties, in order to integrate certain functions. For example, it may have a composition and/or comprise means for carrying out one or more of the following functions: odor control, fungicidal control, moisture absorption, skin healing, imperviousness or water-repellency (property of being impervious to a certain extent), resistance to the intrusion of foreign bodies, abrasion resistance, and elasticity.

Moreover, one or more of these properties can only affect one or more localized portions of the sock. For example, a portion may have properties enabling it to resist the intrusion of foreign bodies, which may not be necessary on other portions. As another example, a portion may have imperviousness, which may not be necessary on another portion.

Accordingly, the textile used for the element 2 and for the above method may be uniform, have specific local, physical and/or chemical properties, in order to integrate one or more of the above functions.

Now described with reference to FIGS. 3A-3E are various embodiments of a reinforcing structure 3 which can be used in the making of a shoe or an article of footwear according to the invention.

Each of these various examples is made of a fiber-based material, for example polyamide, polyurethane, or any equivalent material, and is adapted to form a portion of the sole assembly and lateral reinforcing means of the boot. In a non-limiting fashion, the structure 3 may be obtained by molding a thermoplastic elastomeric material, or may be obtained by any technique known to one with ordinary skill in the art.

Thus, FIG. 3A shows a first example of such a reinforcing element 3, comprising a flexible portion forming the sole 30, demarcated by edges 30′, 30″, and lateral reinforcing elements 31-36, a first end of which is attached to one of the edges 30′, 30″ of the sole 30, while the other end may comprise means 31 a-36 a forming keepers for passage of one or more straps or cords 37, adapted to form one or more laces, for example of the type ending with a tightening element 39, as shown in FIG. 3C. Each of the lateral reinforcing elements preferably has a shape as illustrated in FIG. 3A, which extends away from the end which is opposite the corresponding edge 30, 30′ of the sole 30 to that which is directly connected to the edge of the sole. This shape makes it possible to have a more efficient reinforcing means in the lateral zones.

Due to its shape of a thin fiber layer, the sole 30 is flexible, preferably along two directions, one perpendicular to the axis of the foot, and the other along this same axis. This results in enhanced adaptability in view of the subsequent steps.

In the embodiment of FIG. 3A, the sole 30 is planar and is limited neither in its front portion, nor in its rear portion. Therefore, it demarcates no foot end zone, nor any zone forming a stiffener for the foot.

The embodiment shown in FIG. 3B comprises all of the elements described above with reference to FIG. 3A (for this reason, these elements are not described again), but it further comprises, at the front end of the sole, an element 40 forming a toe-cap and demarcating the end position of the forefoot. As with the previous embodiment, this reinforcing element has no limitation in the rear zone of the foot and, in particular, no element defining a stiffener. This front element 40 is constituted by a band, also made of a fiber-based material, arranged substantially perpendicular to the plane defined by the sole.

The embodiment of FIG. 3C comprises a zone 40 demarcating the end position of the forefoot, as well as a rear zone 42 forming a stiffener and connected to at least a portion of the reinforcing elements 31-36 by lateral fiber plies 43, 43′ which, while retaining a certain flexibility, also provide the rear portion with a certain strength or rigidity. The other elements shown in this FIG. 3C are identical or similar to those already described above with reference to FIGS. 3A and 3B.

The embodiment of FIG. 3D is a variation of that of FIG. 3C. A structure comprising lateral reinforcing means, a toe-cap 40, and a rear stiffener 42, is still achieved, but this time in two portions, by combining the structure of FIG. 3A and the structure shown in FIG. 3E. The latter comprises a portion 30 a forming a sole, a toe-cap 40, a rear portion 42 forming a stiffener, and lateral elements also forming a reinforcing means in the form of lateral fiber plies 43 a, 43 a′. The structure of FIG. 3A can be inserted in this portion until, for example, the front edge of the sole 30 thereof comes into contact with the inner surface of the toe-cap 40. A reverse assembly is also possible, in which it is the structure of FIG. 3E which is inserted in the structure of FIG. 3A until the upper portions of the reinforcing elements 31-34 thereof substantially coincide with respective portions of the edges 430, 430′ of the lateral fibrous plies 43 a, 43′a.

Now described is how a shoe can be made from the various elements that have already been described above.

To this end, a form or preform is used, such as the solid form 50 shown in front view and in side view in FIGS. 4A and 4B, respectively. This form assumes the contours of a foot.

The textile element FIGS. 1A and 1B can be fitted onto this form to obtain the intermediate element shown in FIGS. 5A and 5B. The front end portion 12 of the sock comes into contact with the forefoot, the portion 10 covers the foot itself, the portion 14 comes into contact with the heel, and the upper 16 surrounds the ankle, the second heel 18 being in contact with the rear upper portion thereof. The assembly is extended by the second upper 20.

One of the reinforcing elements of FIGS. 3A-3E is positioned on this assembly: the composite element of FIG. 3D has been selected here. The front portion of the foot of the form 50 (fitted with the sock) is positioned against the inner surface of the toe-cap 40 and the stiffener 48 is positioned against the rear of the heel of the form 50. In view of the flexibility of the constituent fiber-based material of the reinforcing elements thus positioned, the latter can be adapted to the shape defined by the solid element 50. In addition, the structure of the reinforcing means of FIG. 3D has an advantage, in that the two portions, front and rear, can possibly slide with respect to one another, thus enabling the reinforcing structure to be adapted to the size defined by the form 50.

As seen in FIGS. 6A and 6B, the opening 21, made in the second upper 20 of the sock, enable passage therethrough of the cord(s) which subsequently will make it possible to close the shoe.

These two elements, the sock made of textile material and the reinforcing element, can be assembled, for example by gluing, the assembly thus forming a non-reversible structure. Alternatively, the assembly can be subjected to a heating step, in order to achieve a fusion of the material of the reinforcing structure and the material of the sock 10.

In an alternative embodiment, the sock made of textile material and the reinforcing element can be reversibly assembled. For example, the surfaces to be assembled to one another are connected by means such as snap-fasteners, buttons, and hook-and-loop surfaces of the Velcro® type, arranged in the zones adapted to come into contact with one another.

During a subsequent step, and as illustrated in FIGS. 7A and 7B, the portion forming the second upper 20 can then be pulled onto the foot, this step requiring only a simple manipulation by an operator. The operator grasps the edges of the end opening 22 of the sock and gradually pulls the portion forming the second upper 20 on both the upper portion of the foot and the zone forming the sole.

The operator continues this operation until the opening 22 reaches the front end of the sock, to form an assembly such as that shown in FIG. 7C. The second heel 18 then covers the first heel 14, which is located in the first textile layer, in contact with the form 50. The cord 37 and its tightening means 39 remain accessible through the opening 21.

It is also possible to reinforce the assembly thus obtained, by further adding a reinforcing layer, that is to say, by inserting the structure of FIG. 7C in a second reinforcing structure, from one of the types already described above with reference to FIGS. 3A-3E.

An article of footwear has thus been achieved, which may possibly be completed by a sole 52, for example by gluing, stronger than the fiber-based material portion 30 of the reinforcing element (see FIG. 8).

The assembly obtained with or without a sole 52, is extremely light, because it only comprises two textile layers and one or more reinforcing elements made of fibrous material, which is/are very fine and very light. This structure therefore comprises two “skins”, between which one or more reinforcing elements are arranged.

As understood from reading their description, the operations do not implement any stitching step, or any difficult step of positioning elements with respect to one another. It is therefore possible to achieve an article of footwear, or a shoe, in a very simple, very fast, and very economical fashion.

Exemplary embodiments given above implement a sock of the type described with reference to FIGS. 1A and 1B, that is to say, with two uppers 16, 20.

In another example of embodiment, shown in FIGS. 9A and 9B, a simple sock is used with a single upper 16. This sock is fitted onto the form 50 of FIGS. 4A and 4B. Then, as in the step of FIGS. 6A and 6B, a reinforcing structure, for example of the type of one of those described above with reference to FIGS. 3A-3E, is applied to the assembly. The textile element and the reinforcing element(s) are then assembled permanently (for example by gluing and/or heating) or reversibly, for example by means such as snap-fasteners, buttons, and hook-and-loop surfaces of the “Velcro®” type, arranged in the zones adapted to come into contact with one another.

The structure of FIG. 9B is thus obtained, which may be completed by a sole 52, such as that shown in FIG. 8.

For this other example of embodiment, a material having one or more physical and/or chemical properties can also be used, as a textile material of the sock, in order to give it one of the functions already mentioned above. In addition, such property or properties may be homogeneous on the entire textile material, or localized to only a portion thereof.

It has been shown that the textile element 2 can be manufactured integrally, in the sense that the first portion and the second portion are made in direct continuity with one another. Alternatively, however, the textile element 2 may comprise two or more portions affixed to one another by any appropriate means, such as stitching. 

1. A textile element (2) comprising a sock foot (10), a first heel (14), a first upper (16), a second heel (18) arranged at the top of said upper, substantially symmetrical to the first heel (14) in relation to a plane perpendicular to the axis of the upper, and a second upper (20), in the extension of the second heel (18).
 2. Textile element according to claim 1 further comprising an opening (21) made in the second upper in order to provide a passageway for one or more lacing cords (37).
 3. Textile element according to claim 1, at least a portion of the textile material comprising one or more physical and/or chemical properties enabling it to ensure odor-control, fungicidal control, moisture absorption, skin healing, imperviousness or water-repellency, resistance to intrusion of foreign bodies, resistance to abrasion, elasticity, or the like.
 4. Textile element according to claim 1, the second upper (20) being stitchlessly connected to the first upper.
 5. A shoe comprising, from within of the shoe, a first flexible textile layer (10, 16) forming a sock, and a reinforcing structure (3) in which the textile layer is arranged and to which it is fixed by fixing means.
 6. Shoe according to claim 5, the textile layer being arranged: removably with respect to the reinforcing structure, to which it is connected using means such as snap-fasteners, buttons, hook and loop surfaces, or the like; or irremovably with respect to the reinforcing structure, to which it is connected by gluing or heat sealing.
 7. Shoe according to claim 5, further comprising a second textile layer (20), the reinforcing structure being arranged between the first textile layer (10, 16) and the second textile layer (20).
 8. Shoe according to claim 7, the second textile layer (20) being obtained in continuity with the first textile layer (10, 16), stitchlessly to connect of the first and second textiles layers.
 9. Shoe according to claim 5, the reinforcing structure comprising at least one sole (30) and lateral reinforcing element (31-36).
 10. Shoe according to claim 9, the reinforcing structure further comprising at least one top-cap element (40) and one stiffener-forming element (42).
 11. Shoe according to claim 5, the reinforcing structure being flexible.
 12. Shoe according to claim 5, the reinforcing structure being made of a fiber-based material.
 13. Shoe according to claim 5, at least a portion of the textile material of the first textile layer (10, 16) and/or of the second textile layer (20) comprising one or more physical and/or chemical properties enabling it to ensure odor control, fungicidal control, moisture absorption, skin healing, imperviousness or water-repellency, resistance to the intrusion of foreign bodies, resistance to abrasion, elasticity, or the like.
 14. Shoe according to claim 13, at least two zones of the textile material having one or more different physical or chemical properties.
 15. Shoe according to claim 14, at least two zones of the textile material can be zones having different levels of imperviousness.
 16. A method for making a shoe using a sock (2) and a reinforcing structure (3) comprising at least one sole (30) and at least one lateral reinforcing structure (31-36, 43, 43′), comprising the steps of: fitting the sock onto a foot-shaped form (52); positioning the reinforcing structure on the sock, in contact therewith, and fixing it to said sock using fixing means.
 17. Method according to claim 16, in which the sock is a textile element comprising a sock foot (10), a first heel (14), a first upper (16), a second heel (18) arranged at the top of said upper, substantially symmetrical to the first heel (14) in relation to a plane perpendicular to the axis of the upper, and a second upper (20), in the extension of the second heel (18).
 18. Method according to claim 16, in which the reinforcing structure is fixed to the sock irremovably, by gluing, heat sealing, or the like.
 19. Method according claim 16, in which the reinforcing structure is fixed to the sock removably by means such as snap-fasteners, buttons, hook-and-loop surfaces, or the like.
 20. Method according to claim 16, in which the reinforcing structure comprises a first portion and a second portion which, prior to attachment to the sock, are displaceable with respect to one another, so as to adjust the reinforcing structure to the foot-shaped form. 